Returnable carton

ABSTRACT

A totally returnable carton has a collapsible material mounting assembly containable internally of the collapsible return carton whether the carton is collapsed or uncollapsed. When it is collapsed, the material mounting assembly fits into the base of the collapsed returnable carton and when it is uncollapsed it fits internally of the extended returnable carton to provide a material mounting tube whose wall panels reinforce the extended walls of the returnable carton.

United States Patent 1191 Miller 5] June 18, 1974 RETURNABLE CARTON 2,642,989. 6/1953 Keiser, Jr. et al 206/52 R 2,782,911 2/1957 Fisher 206/65 R X [751 Invent James M111" Boonvlne 3,148,821 9/1964 Gardiner 229/41 R 73 Assignee; T General Tire & Rubber 3,438,562 4/1969 Connor et a1. 229/41 R Company, Akron, Ohio I Primary Examiner-William 1. Price [22] Flled June 1972 Assistant Examiner-Bruce l-l. Bernstein [21] Appl. No; 266,001 Attorney, Agent, or Firml-lar ry F. Pepper, Jr.; F. C.

h Rote, Jr. [52] US. Cl. 229/41 R, 206/372, 229/23 R [51] Int. Cl B65d 5/36, B65d 13/04 ABSTRACT [58] Fleld of 229/23 41 14 A totally returnable carton has a collapsible material 229/52 41 206/65 46 H mounting assembly containable internally of the collapsible return carton whether the carton is collapsed [56] R cued or uncollapsed. When it is collapsed, the material UNlTED STATES PATENTS mounting assembly fits into the base of the collapsed 577,198 2/1897- Mc'Fadyen 229/41 R returnable Carton and when it is uncollapsed it fits 797,201 8/1905 Hale 229/41 R ternally of the extended returnable carton to provide a 903,555 11/1908 Ferres. 229/41 R material-mounting tube whose wall panels reinforce 1,384,065 7/1921 Hll'SCllWltZ 229/41 R the extended walls of the returnable arton 1,640,452 8/1927 Knowlton 206/65 R 2,164,506 I Enrich 229/23 A X 2 Claims, 6 Drawing Figures 1 RETURNABLE CARTON BACKGROUND OF THE. INVENTION general and in particular to totally returnable cartons for shipping material, which cartons have substantially larger extended shipping volumes than collapsed return volumes.

2. Description of the Prior Art Shipping of materials from point of manufacture to points of assembly involves the continuous use of substantially duplicate containers for such materials. Upon receipt of the materials by the assembler, the containers are scrapped, resulting in added cost of scrap and refuse removal as well as remaining an eyesore and a safety hazard until such refuse removal takes place. When refuse is removed from the assemblers plant, it is merely relocated to a dump or is incinerated with either alternative causing immediate pollution of the environment as well as being a source of other ecological problems. 7

To alleviate these problems returning of the shipping cartons by the assembler to the manufacturer for reuse in the next shipment has been attempted. This was unfeasible from a cost standpoint since the empty cartons take up the same amount of valuable storage space as material filled cartons and are as bulky to handle and ship as the filled cartons. The problems associated with bulky containers are even more aggravated when the shipped material is relatively fragile and requires carton internal packaging during shipment such as carton reinforcers, material holders, or material isolators which retain the shipped material snug within the shipping container and leave a protective space between the outside walls of the container and the material contained therein.

Collapsible return containers are presently known which provide collapsible outside walls to minimize the volume and bulk of the empty container when it is col lapsed. Such containers are disclosed in U.S. Pat. No. 3,438,562, issued to W. G. Connor, et al., as .well as U.S. Pat. No. 3,503,550 and 3,611,994, issuedto J. W. Main et al. and Everett R. Bailey, respectively. Such returnable cartons are useful for bulk shipping of nonfragile materials which require no internal material reinforcing and/or mounting. Where internal packaging is required during the shipment of material, this packaging does not fit into the collapsed container and must be disposed of before the carton is capable of being collapsed and returned to the manufacturer. These internal parts are scrapped and the removal cost and associated ecological problems previously mentioned are thereby only partly solved by using such returnable cartons.

The extent of internal reinforcing and mounting required generally for fragile materials is especially required in shipping magnetic refrigerator or freezer gaskets. These gaskets are assembled into a one piece gasket of rectangular shape ready to be shipped to a manufacturer where they are assembled to a refrigerator or freezer door. This rectangular shape must be maintained throughout shipping to prevent sagging and setting of the gasket into irregular patterns which would not fit the intended doors and adversely affect the required seal thereby. These gaskets also have a decorative color coordinated external coating of thermoplastic which must be protected from any skuffing, cracking or puncturing from movement within the carton. To meet these requirements necessitates a shipping carton having complicated internal packaging for the shipped gaskets. The material of the internal packaging therefore maybe even greater than the material used for the external shipping carton. In those cases, the use of a reuseable external carton does not even begin to solve the problems of cost and refuse generally associated with material shipment.

SUMMARY OF THE INVENTION According to one mode of the present invention, a totally returnable, collapsible carton is provided which solves all the previously mentioned problems and others by including material mounting means internally of the returnable carton for locating the shipped material thereon, which means is also collapsible to fit within the base of the collapsed returnable carton.

The material mounting means includes a number of wall panels which reinforce the extended walls of the uncollapsed carton and which also fit into the base of the collapsed carton. These wall panels have a collapsible locking device on one side allowing a collapsible tubular device, upon which the shipped material may be threaded, to fit between two of such wall panels thereby maintaining both the tubular device and the panel locking devices rigidly extended.

The invention obviates the need for scrapping any intemal packaging material and allows a complete carton to be collapsed down to a minimal size after the material therein is removed. The collapsed external carton with the internal packaging located internally therein is retumable to the manufacturer who extends it for reuse BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 depicts a perspective view of a partially cut away uncollapsed returnable carton.

FIG. 2 depicts an expanded perspective view of a partially cut away uncollapsed material mounting assembly found in FIG. 1.

FIG. 3a depicts an expanded perspective view of the wall panel found in FIG. 2 with the locking assembly collapsed.

FIG. 3b depicts an expanded perspective view of the collapsed mounting tube found in FIG. 2.

FIG. 30 depicts an expanded perspective view of the collapsed wall insert found in FIG. 1.

FIG. 4 depicts a side sectional view of the collapsed returnable carton of FIG. 1 with collapsed internal packaging therein.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings wherein the showings are for the purpose of depicting the preferred embodiment of the invention and not for the purpose of limiting same, FIG. 1 has a returnable carton assembly having a rigid noncollapsible base 12, a collapsible wall insert 14, a noncollapsible cover 16 and a collapsible material mounting assembly 18.

The wall insert 14 is fitted into the base 12 to lie against rigid walls 13 of the base 12 and extend the enclosure of the carton 10. The top cover 16 is fitted over the wall insert 14 to have sides 17 of the cover 16 overlap the insert 14. This forms the external container of the reusable carton 10.

The material mounting assembly 18 is mounted internally of the external container and is comprised of a pair of wall panels 20 between which is mounted a tube 22 upon which shipping material is located. The shipping material may be comprised of any material which requires isolation from the external container, such as refrigerator or freezer gaskets 24. These gaskets 24 are threaded upon the tube 22 and are retained by the wall panels 20.

A similar material mounting assembly 18 is located adjacent the assembly 18 to have wall panels 20, 20 abutt against each other in the area where a crease is located on the wall insert 14. It will be understood that like numbers refer to like parts in construction and function, and although two assemblies 18, 18' are shown abutting within the external container, any multiple number of such assemblies 18 could be enclosed. Furthermore, such assemblies could be configured in various configurations, including next to each other, on top of each other, perpendicular to each other or any combination thereof, so long as they are retained within the external container. The depicted arrangement of two assemblies 18, 18' provides added reinforcement to the wall insert 14 in the area weakened by the crease 15 through the abutting panels 20, pressing against the wall insert 14 to prevent it from collapsing as well as pressing it against the walls 13.

The wall insert 14 has hand holes 19 located on each side thereof to facilitate lifting and movingof the returnable carton 10. The placement of the hand holes 19 is dependent upon how the carton is to be handled and their locations and methods of making them are obvious to those skilled in the art.

Referring now to FIGS. 2 and 3, each wall panel 20 of assembly 18 has a tube locking assembly 26 located on one of its faces. The locking assembly 26 is affixed to the panel 20 through flanges 28 by means known to those skilled in the art, such as adhesive bonding or mechanical anchoring. A collapsible tube insert 30 is collapsed down into the plane of the panel 20 or is extended to form a rectangular bridge structure which presses into one of the ends of extended tube 22.

The tube 22 is open ended and collapses into a plane defined by any one of its sides unless the open end of the tube is supported by having the tube insert 30 of the locking assembly 26 pressed into its extended open end.

The wall insert 14 is also open ended and may be collapsed transversally into the plane of any of its sides, or alternatively the two opposite sides having creases 15 may be pushed in at the creases 15 to collapse the remaining sides unto each other sandwiching the creased sides therebetween. The latter method allows the wall insert 14 to be collapsed into a smaller area plane which is easier to store within the base 12 of the collapsed returnable carton 10.

Referring now to FIG. 4, the collapsed carton 10 has the wall insert 14, the wall panels 20, and the tubes 22 all collapsed and located within the sidewall 13 confinement of the base 12. The sidewalls 17 of the cover 16 telescope over the sidewalls 13 of the base 12 to form a compact returnable carton having all the internal packing parts located therein.

In use the mounting assembly 18 is constructed by extending the collapsed mounting tube 22 into a rectangular shape by pressing against opposite corner lines 23. The tube insert 30 of the locking assembly 26 is extended into a rectangular bridge by pushing against the side of the tube insert 30 overlapping the flange 28 in along the pivot line 29. The extended tube insert 30 is then pressed into one open end of the extended tube 22. The tube insert 30 in its extended position is identical to the open ended area and configuration of the open end of tube 22 and upon mating each retains the extended configuration of the other since their respective pivot lines 29 and comer lines 23 are at right angles to each other preventing each from collapsing along said lines 23, 29.

Refrigerator or freezer gaskets 24 are then threaded over the expanded tube 22 until the tube 22 is filled. The other open end of the tube 22 is then similarly mated with a second panel 20 to prevent any gasekts 24 from sliding off the tube 22. Similarly, the assembly 18 is likewise constructed and threaded with gaskets 24.

The wall insert 14 is next extended into a rectangular shape by pushing against creases 15 and placed into the base 12 to fit against the rigid sidewall 13 of the base 12.

The loaded material assemblies 18, 18' are then placed inside of the extended wall insert 14 and base 12. The wall panels 20 are of the same substantial area and configuration as one side of the extended wall insert 14 and thereby reinforce the wall insert 14 and maintain its extended shape by pressing it against the rigid walls 13 of the base 12. Since the wall insert 14 has folding creases 15 to facilitate collapse, wall panels 20, 20' are made to abutt in the area of the creases 15 and provide added reinforcement and extended shape retention to the insert 14 in that area.

The cover 16 is then placed over the open end of wall insert 14 and the returnable carton assembly 10 is secured by means familiar to those skilled in the art, such as banding to make it ready for shipment.

When the returnable carton is received, the securing means and cover 16 are removed and the material assemblies 18, 18' are lifted out of the carton 10. One wall panel 20 is retracted from each of the tubes 22, 22 and the gaskets 24 are stripped from the tubes 22, 22. The remaining wall panels 20 are removed from the ends of the tube 22 and all the panels 20 are collapsed. The wall insert 14 is removed from the base 12 and collapsed by pushing in along the creases 15. The collapsed parts are fitted within the sidewalls 13 of the base 12 and the cover 16 is telescoped over side walls 13. The collapsed assembly is then secured and shipped back to the manufacturer for reuse in the next shipment.

provements and modifications be included within the scope of this specification. What is claimed is: 1. A totally returnable spring shipping carton having a collapsed return volume substantially smaller than its uncollapsed shipping volume comprising:

A. an outer structure consisting essentially of:

l. a non-collapsible base member having rigid sidewalls and one open end, 2. a collapsible open ended, rectangular, tubular wall member mounted against said sidewalls in its uncollapsed condition to extend the enclosure of said sidewalls and adapted to position within said base member in its collapsed condition, and 3. a non-collapsible cover membercovering the open end of said tubular member in its uncollapsed condition and adapted to cover the open end of said base member when said carton is collapsed; and B. at least one inner collapsible material mounting structure consisting essentially of 1. a pair of spaced, wall panels mounted internally of said tubular wall member in its uncollapsed condition and adapted to position within said base member in said cartons collapsed condition, and

2. a collapsible, open ended, rectangular, tubular mounting member extending when uncollapsed between said panels and adapted when collapsed to position within said base member, and

3. collapsible locking means located on one face of said wall panels for attaching said mounting member thereto, said locking means comprising a rectangular flat sheet having a rectangular bridge extending therefrom in its uncollapsed condition and a flat plane in its collapsed condi tron.

2. A totally returnable carton as set forth in claim 1 wherein the rectangular bridge of said locking means is pressed into the open end of said mounting member to prevent the collapse of both said locking means and said mounting member. 

1. A totally returnable spring shipping carton having a collapsed return volume substantially smaller than its uncollapsed shipping volume comprising: A. an outer structure consisting essentially of:
 1. a non-collapsible base member having rigid sidewalls and one open end,
 2. a collapsible open ended, rectangular, tubular wall member mounted against said sidewalls in its uncollapsed condition to extend the enclosure of said sidewalls and adapted to position within said base member in its collapsed condition, and
 3. a non-collapsible cover member covering the open end of said tubular member in its uncollapsed condition and adapted to cover the open end of said base member when said carton is collapsed; and B. at least one inner collapsible material mounting structure consisting essentially of
 1. a pair of spaced, wall panels mounted internally of said tubular wall member in its uncollapsed condition and adapted to position within said base member in said carton''s collapsed condition, and
 2. a collapsible, open ended, rectangular, tubular mounting member extending when uncollapsed between said panels and adapted when collapsed to position within said base member, and
 3. collapsible locking means locaTed on one face of said wall panels for attaching said mounting member thereto, said locking means comprising a rectangular flat sheet having a rectangular bridge extending therefrom in its uncollapsed condition and a flat plane in its collapsed condition.
 2. a collapsible open ended, rectangular, tubular wall member mounted against said sidewalls in its uncollapsed condition to extend the enclosure of said sidewalls and adapted to position within said base member in its collapsed condition, and
 2. A totally returnable carton as set forth in claim 1 wherein the rectangular bridge of said locking means is pressed into the open end of said mounting member to prevent the collapse of both said locking means and said mounting member.
 2. a collapsible, open ended, rectangular, tubular mounting member extending when uncollapsed between said panels and adapted when collapsed to position within said base member, and
 3. a non-collapsible cover member covering the open end of said tubular member in its uncollapsed condition and adapted to cover the open end of said base member when said carton is collapsed; and B. at least one inner collapsible material mounting structure consisting essentially of
 3. collapsible locking means locaTed on one face of said wall panels for attaching said mounting member thereto, said locking means comprising a rectangular flat sheet having a rectangular bridge extending therefrom in its uncollapsed condition and a flat plane in its collapsed condition. 